Photovoltaic Module Back Sealing With Pulsed IR Repair Curing
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Solution Overview
Problem
The existing methods for repairing photovoltaic modules are ineffective due to the porosity of the back foils, which leads to water penetration and short-term adhesion of new foils, resulting in frequent failures and impracticality, especially with large-scale repairs.
Innovation Solution
A method involving a continuous process with seven stages: anonymization, cleaning, drying, coating with a liquid plastic sealing compound, treating with pulsed infrared radiation for rapid polymerization, and functional testing, significantly reducing crosslinking time from 60 minutes to 3 minutes, ensuring a durable and hermetic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional glueing method is used to repair photovoltaic modules, then the repair process is simple, but the adhesion is poor and the repair duration is short due to water penetration through porous back foils
Solution Approach 1:
The patent changes the physical-chemical parameters of the sealing compound by using thermoplastic materials with specific melting points and flow characteristics. The sealing compound is heated to become viscous and flow into the porous back foil structure, then cooled to solidify and form a strong bond. This parameter transformation enables both simple application and reliable adhesion.
Solution Approach 2:
The patent utilizes phase transitions of the thermoplastic sealing compound between solid, liquid, and semi-solid states. During application, the compound transitions from solid to viscous liquid when heated, allowing it to penetrate and bond with the back foil. Upon cooling, it transitions back to solid, creating a durable seal that resists water penetration and maintains adhesion over time.
2Device complexity
If manual repair methods are used for photovoltaic modules, then the equipment complexity is low, but the productivity is low and automation extent is insufficient
Solution Approach 1:
The patent divides the repair process into distinct sequential stages: cleaning, heating, application of sealing compound, cooling, and quality inspection. Each stage is handled by specialized equipment modules that can be independently optimized and maintained. This segmentation enables high-speed automated processing while keeping individual device components relatively simple and manageable.
Solution Approach 2:
The patent replaces manual mechanical operations with automated systems. Robots or automated conveyors handle module positioning, cleaning mechanisms automatically remove contaminants, and precision heating elements apply controlled thermal energy. The sealing compound application is automated through controlled dispensing systems, eliminating manual labor and significantly increasing productivity.
3Use of energy by stationary object
If conventional sealing methods are used for photovoltaic modules, then the energy consumption is high due to long crosslinking time of about 60 minutes, but the sealing quality is insufficient
Solution Approach 1:
The patent employs periodic or cyclic heating and cooling cycles rather than continuous prolonged heating. The thermoplastic sealing compound is heated rapidly to its melting point, held at temperature for a brief period to ensure complete penetration and bonding, then quickly cooled to solidify. This periodic thermal action achieves superior sealing quality in minutes rather than hours, dramatically reducing energy consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves a 20-fold acceleration in sealing time, reducing energy consumption and ensuring the repaired modules remain functional for at least ten years with above-average quality and durability.
Implementation Method 1
treating with pulsed infrared radiation for rapid polymerization
Implementation Method 2
treating with pulsed infrared radiation for rapid polymerization
Implementation Method 3
removing the further still-remaining water on the back side of the photovoltaic modules facing upwards by drying same using pulsed infrared radiation
Data Source
AI summary
A method for efficiently sealing the back of photovoltaic modules as part of a repair. The photovoltaic modules pass through several process stages one after another, beginning with a selection of repairable photovoltaic modules, their anonymization and cleaning, followed by further process stages. The further process steps include drying, coating, and treating the coating with pulsed infrared radiation. The process is completed with a check of the process and a functional test using a flash test. The process conditions and apparatus configurations in the process stages are described in detail.